Inflatable air support surface and support element

ABSTRACT

An air inflatable support element includes: (a) two identical circular outer sections, one being an upper outer section and the other being a lower outer section; and (b) two or more circular middle sections, each middle section being affixed at its periphery to the adjacent middle section, each middle section being identical to the other middle sections, each middle section being affixed to an outer section; wherein the outer sections are parallel, but not affixed, to one another; the outer and middle sections each include an identically sized central aperture, the central aperture extending through the center of the support element; and the support element includes a flexible, nonmetallic material. Also included is an air support surface containing the support elements.

BACKGROUND OF THE INVENTION

[0001] 1. Technical Field:

[0002] The present invention relates to an inflatable air support surface and support element, particularly an air mattress, seat cushion, or the like for supporting a human or animal body, or parts thereof, the support surface comprising a number of adjacent, doughnut-shaped support elements, which can be filled with air or some other flowing medium, the elements being arranged in rows within the support surface.

[0003] 2. Background Information:

[0004] Inflatable support surfaces other than very simple inner tube-type products must have internal supports, such as metal coil springs, in order to determine the final configuration when they are inflated. Prior to the present invention, support surfaces were largely constrained in a manner which transferred stress across these internal supports in an arbitrary, nonuniform manner. The desire for uniform, predictable distribution of stress across internal supports yielded the present invention.

[0005] In the present invention, circular internal support elements distribute stress evenly around the element, resulting in a more comfortable, longer lasting support surface.

BRIEF SUMMARY OF THE INVENTION

[0006] The present invention includes an air inflatable support element, and an air support surface containing the support elements. The support element comprises:

[0007] (a) two identical circular outer sections, one being an upper outer section and the other being a lower outer section; and

[0008] (b) two or more circular middle sections, each middle section being affixed at its periphery to the adjacent middle section, each middle section being identical to the other middle sections, each middle section being affixed to an outer section;

[0009] wherein the outer sections are parallel, but not affixed, to one another; the outer and middle sections each comprise an identically sized central aperture, the central aperture extending through the center of the support element; and the support element is substantially comprised of a flexible, nonmetallic material.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0010] A more complete understanding of the invention and its advantages will be apparent from the following detailed description taken in conjunction with the accompanying drawings, wherein examples of the invention are shown, and wherein:

[0011]FIG. 1 shows a perspective view of a support element according to the present invention;

[0012]FIG. 2 is a top plan view of the support element according to FIG. 1; the bottom plan view being identical to the top plan view;

[0013]FIG. 3 is a bottom plan view of an air support surface according to the present invention;

[0014]FIG. 4 is a top plan view of the air support surface according to FIG. 3;

[0015]FIG. 5 is a side elevational view of the air support surface according to FIG. 3;

[0016]FIG. 6 is a cross-sectional view of FIG. 5; taken along lines 6-6;

[0017]FIG. 7 is a cross-sectional view of a support element according to the present invention, shown in an air support surface;

[0018]FIG. 8 is an elevational view of an end of the air support surface according to FIG. 3;

[0019]FIG. 9 is a cross-sectional view of the air support surface of FIG. 8, taken along line 9-9;

[0020]FIG. 10 is a detail view of a comer of the air support surface of FIG. 6;

[0021]FIG. 11 is a detail view of a gusset of the air support surface of FIG. 6;

[0022]FIG. 12 is a detail view of a weld zone of the air support surface of FIG. 6;

[0023]FIG. 13 is a detail view of the lower portion of a support element in the air support surface of FIG. 6; and

[0024]FIG. 14 is a perspective view of an alternate embodiment of an air support surface according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0025] In the following description, like reference characters designate like or corresponding parts throughout the several views. Also, in the following description, it is to be understood that such terms as “top,” “bottom,” “within,” and the like are words of convenience and are not to be construed as limiting terms. Referring in more detail to the drawings, the invention will now be described.

[0026] Turning first to FIGS. 1 and 2, a circular air support element, generally referred to as 10, according to the present invention is shown in an inflated position in FIG. 1, and a deflated position in FIG. 2. The inflatable air support element 10 is ordinarily in a flat, circular, deflated position unless it is contained in an inflated air support surface, generally referred to as 20, such as a mattress, cushion, or chair. The support element 10 is made of a flexible, sturdy material, preferably plastic or plastic-like material, capable of being supported by air pressure. While rows of metal springs are utilized in many conventional mattresses, a plurality of side by side support elements 10, preferably rows of identical support elements, is incorporated into the present air support surface 20. The air support surface of the present invention does not include or require any rigid metal springs. In fact, no metal components are required herein.

[0027] In the preferred embodiment illustrated in FIGS. 1 and 2, the support element 10 is basically comprised of three sections: two identical, circular outer sections, one of which ends up being the upper, outer section 11 near the upper surface when it is incorporated into the air support surface 20, and the other of which ends up as the lower, outer section 12, near the bottom surface of the air support surface. The top (see FIG. 2) and bottom plan views of the preferred embodiment of the support element 10 are therefore mirror images of each other. The third, middle section of the support element 10 is comprised of two or more identical, circular discs: an upper middle section 13, and a lower middle section 14. The upper middle section 13 is sealed to the lower middle section 14 along their outer edges, forming a middle seam 15. The upper middle section 13 is the section of the support element that is above the middle seam 15 and below the upper outer section 11. Similarly, the lower middle section 14 is the section below the middle seam 15 and above the lower outer section 12. The diameter of the middle sections 13, 14 is preferably a few inches (about five centimeters), more preferably about a third, larger than the diameter of the outer sections 11, 12. When the air support surface 20, and therefore the support elements 10 within the support surface, are inflated, the support elements are generally cylindrical, forming the shape shown in FIG. 1 (which resembles a spindle during meiosis). The area within the extended, inflated support element 10 is in the general shape of a column.

[0028] The diameter of the middle sections 13, 14, and the height of the support element 10 when it is inflated, are preferably approximately equal. The height of each inflated support element is preferably approximately equal to the thickness of the support surface, since the support elements preferably extend approximately from the top of the support surface to the bottom. The inflated support elements 10, though, can be of any dimensions, from about one inch, or about 2.5 centimeters, in height, to several yards in height, depending on the desired configuration of the support surface.

[0029] As illustrated in FIGS. 1 and 2, each outer section 11, 12 comprises a central aperture 16 at the center. The central aperture 16 preferably has approximately the same diameter as a pencil, which is about one centimeter, although it can be of any diameter. When the support element 10 is inflated or deflated, the upper and lower central apertures 16 are directly on top of one another. The middle sections also comprise the central apertures in the same location, so a deflated support element gives the appearance of a flattened Frisbee with a hole in the middle. Surrounding each central aperture 16 is a circular groove 17 formed in the outer section 11, 12. The circular groove 17 is formed when the outer section 11 or 12 is welded to the middle section 13 or 14, respectively, during manufacture of the support element 10. However, the outer section could be glued or otherwise sealed to the respective middle section. The middle section may also comprise one or more circular peripheral apertures 18. The support element preferably comprises an even number, most preferably between about two and eight, of evenly spaced, same-sized peripheral apertures 18, with matching apertures close to the periphery of each middle section 13, 14. A particularly preferred embodiment comprises three evenly spaced, identical peripheral apertures 18, each with a diameter of about ½ centimeter, approximately one centimeter from the middle seam 15 on each middle section 13, 14. When the support element 10 is inflated, the peripheral apertures 18, then, are on either side of, and close to, the middle seam 15 (equator).

[0030] When the support surface 20 is inflated by air from a pump, stress is conveyed in a vertical orientation up and down the middle section 13, 14 of each support element, leaving vertical striations 19 within the flexible material of the middle section, as shown in FIG. 1. The air pressure within the vertical column at the center of each support element 10, and the pressure between the support elements 10 in the support surface 20, stretches the material, causes the middle sections 13, 14 to exhibit these vertical stress lines.

[0031] Turning now to FIGS. 3, 4 and 5, an air support surface 20 is shown from the bottom (FIG. 3), top (FIG. 4), and side (FIG. 5). Where the air support surface is a mattress, as shown here, it is approximately the size of a standard twin mattress. A number of support elements 10 are enclosed within the air support surface 20 for supporting the weight of a body on the support surface. The air support surface 20 of FIG. 3 comprises nine rows of three support elements 10 each, although this number and arrangement can vary. For example, an air support surface according to the present invention would function as effectively if the support elements 10 were to be arranged in a random manner or in a snaking pattern.

[0032] The inflatable air support surface 20 is useful for supporting a human or animal (e.g., dog or cat bed) body, or a part thereof. It can be used, for example as a seat cushion for a wheelchair occupant. The circular support element 10 herein is advantageous in that it distributes stress from inflation evenly around the 360 degrees of the area of its attachment to the support surface at both the top and the bottom of the support element. Each support element 10 is self-contained so that if one unit malfunctions, the integrity of the entire air support surface 20 is not compromised.

[0033] Most conventional mattresses have four side walls which are each sewn to a top layer and a bottom layer around the two opposite long edges of each of the side walls in the mattress. Instead of this, the support surface of the present invention comprises a top sheet 21, which wraps around the four sides of the support surface and overlaps a bottom sheet 22, as shown in FIG. 3. The top sheet 21 preferably comprises a soft, textured material layer laminated onto a layer of plastic material, while the bottom sheet 22 is preferably a layer of the plastic material. The plastic material is preferably any radio frequency-weldable thermoplastic material, such as a polyurethane, and is preferably the same material as the support element. When the support surface is inflated, air flowing through the support surface flows through the peripheral apertures of the support elements and the central apertures and forms the domes at the top and the bottom of all of the support elements within the support surface.

[0034] Referring to FIGS. 3, 6 and 12, the edges of the top sheet 21 are sealed to the edges of the bottom sheet 22 at a perimeter 23. As shown in FIG. 3, the perimeter 23, then, remains on the bottom of the bed rather than along the lateral side edges of the support surface. Thus, stress is not as heavily applied at the edges of the support surface. The perimeter seam is less likely to pull apart with wear and tear on the support surface over time. The support surface 20 is more durable because the weld is along the perimeter 23 rather than along each side edge. A cross-section of the perimeter 23, which is shown at the bottom of FIG. 6, is inverted in FIG. 12. FIG. 12 shows the weld 27 between the top sheet 21 and the bottom sheet 22.

[0035]FIG. 5 shows the air support surface of FIGS. 3 and 4 from the side, and FIG. 6 shows a latitudinal cross-section of the support surface 20. The air support surface 20 is enclosed on its top and around its four sides by the top sheet 21, and on the bottom by the bottom sheet 22. Since the embodiment shown has three support elements in each

[0036] Most conventional mattresses have four side walls which are each sewn to a top layer and a bottom layer around the two opposite long edges of each of the side walls in the mattress. Instead of this, the support surface of the present invention comprises a top sheet 21, which wraps around the four sides of the support surface and overlaps a bottom sheet 22, as shown in FIG. 3. The top sheet 21 preferably comprises a soft, textured material layer laminated onto a layer of plastic material, while the bottom sheet 22 is preferably a layer of the plastic material. The plastic material is preferably any radio frequency-weldable thermoplastic material, such as a polyurethane, and is preferably the same material as the support element. When the support surface is inflated, air flowing through the support surface flows through the peripheral apertures of the support elements and the central apertures and forms the domes at the top and the bottom of all of the support elements within the support surface.

[0037] Referring to FIGS. 3, 6 and 12, the edges of the top sheet 21 are sealed to the edges of the bottom sheet 22 at a perimeter 23. As shown in FIG. 3, the perimeter 23, then, remains on the bottom of the bed rather than along the lateral side edges of the support surface. Thus, stress is not as heavily applied at the edges of the support surface. The perimeter seam is less likely to pull apart with wear and tear on the support surface over time. The support surface 20 is more durable because the weld is along the perimeter 23 rather than along each side edge. A cross-section of the perimeter 23, which is shown at the bottom of FIG. 6, is inverted in FIG. 12. FIG. 12 shows the weld 27 between the top sheet 21 and the bottom sheet 22.

[0038]FIG. 5 shows the air support surface of FIGS. 3 and 4 from the side, and FIG. 6 shows a latitudinal cross-section of the support surface 20. The air support surface 20 is enclosed on its top and around its four sides by the top sheet 21, and on the bottom by the bottom sheet 22. Since the embodiment shown has three support elements in each transverse row, three support elements 10 are visible in FIG. 6. FIG. 7 shows an individual support element 10 from the support surface 20.

[0039] Referring to FIGS. 5, 6, 7 and 13, the upper outer section 11 of each support element 10 is welded, or otherwise affixed to, the top sheet 21. Likewise, the bottom sheet 22 is welded to the lower outer section 12 of each support element in the support surface 20. The welds are along the circular periphery of the outer sections 11, 12. This forms slight circular protrusions on the top and bottom surfaces of the mattress (support surface). The circular welds leave an air pocket 24 between the outer section 11, 12 and the top or bottom sheet 21, 22, respectively. FIG. 13 shows the bottom portion of a support element 10, including a peripheral aperture 18, a lower central aperture 16, a lower air pocket 24, and the bottom sheet 22. The central apertures 16, and also the peripheral apertures 18, allow air to flow to the inside of the support element 10 and inflate the upper and lower air pockets 24. Where the top and bottom sheets 21, 22 are made of a substantially permeable material, air is transferred onto and out of the support surface as the user moves about on the support surface. This causes a bellows effect, with small jets of air moving into and out of the air pockets 24. The air transfer inhibits growth of mold and mildew within the support surface, which is particularly advantageous for users with allergies to molds and mildew. The ventilation also reduces any moisture accumulation within the support surface. This is particularly advantageous in humid climates, frequently changing ambient conditions, or for users who perspire heavily.

[0040] The central and peripheral apertures 16, 18 allowing ventilation throughout the support surface also results in therapeutic benefits from the air transfer. This makes the user more comfortable and supports the various body parts independent of one another. The support surface is thus an adjustable, breathable system. Also, the central apertures 16 facilitate manufacture because the support elements 10 are placed on spindles during the manufacturing process, prior to incorporation of the support elements into the finished support surface 20.

[0041] Because the support element is made of a sturdy, flexible material, an air support surface 20 containing the support elements 10 can be manufactured with varying levels of elasticity. The circular support element 10 herein is also advantageous in that each one supplies a consistent, repeatable amount of support, even after years within a support surface. Also, the user can vary air pressure within the support surface, short or long term, by raising or lowering air pressure within the system. Air pressure within the support surface is controllable by means of a detachable pump, such as an axial flow pump, piston pump, centrifugal pump, or diaphragm pump, which is attached to a closable opening or valve in the support surface, usually at one end. The valve or opening can be adapted to fit various pump configurations and capacities.

[0042] Referring to FIGS. 4, 5, and 6, the two long upper edges of the support surface are preferably formed into gussets 25 for helping to contain the user on the support surface. As shown in FIGS. 4 and 5, the two identical anti-roll gussets 25 extend along the two opposite lateral upper edges of the support surface. These bulbous protrusions reduce gapping between support surfaces where two or more support surfaces are enclosed within a single outer covering, as in a queen sized mattress. Two such support surfaces 20 can be incorporated into an outer covering to form a double or queen sized bed capable of accommodating two or more persons. This provides an advantage over conventional double or queen mattresses because, where two people are reclining on the bed, for example, each support surface behaves independently of the other. One person's activities (e.g., tossing and turning) does not have as much effect on the partner in the same bed. For example, a large person can sleep on one support surface, while a small partner can be independently accommodated on the adjacent support surface in the same bed. One lateral gusset tends to overlap the other within the outer covering. When used as a twin sized support surface, or in a queen sized support surface, the gussets 25 provide additional support along the lateral edges of the support surface and help contain the user's body on the support surface. Where the support surface is a mattress, its dimensions preferably correspond to the dimensions of a conventional mattress. The mattress of the present invention can used on any conventional home or hospital bed, or various embodiments can be used without box springs. The present air support surface allows for “customized” support of the various parts of the body, which have different dimensions and requirements. Herein, stress is evenly distributed over each columnar support element.

[0043] As shown in cross-section in FIG. 6, and in detail in FIG. 11, lateral gussets 25 are formed on opposite upper corners of the support surface 20. As illustrated in FIG. 11, a gusset 25 is formed by welding two opposite ends of a second strip 26 of material to the inside of the top sheet 21 at the corners of the support surface 20. Radio frequency welding is preferred for forming the welds 27 of the present invention. The second strip 26 is stretched taut, which pulls the edge into a bulbous shape where a sharper edge would be in a conventional mattress. The gussets 25 do not extend to the ends of the support surface, as can be seen in FIGS. 4 and 5, so they are air filled when the support surface 20 is under pressure.

[0044] Referring to FIGS. 8 and 9, the support surface 20 is shown in longitudinal cross-section in FIG. 9. The cross-section shown in FIG. 9 is taken along line 9-9 in FIG. 8 at the midpoint of the support surface. The vertical striations 19 cause the middle sections to appear in FIG. 9 as petal-like formations around the central aperture 16.

[0045] Referring to FIG. 10, the side walls of the support surface 20 are reinforced with a reinforced butt seam 28. During manufacture, the butt seam 28 is formed by placing the edges of the two side walls 29 side by side and overlying a third segment 30 of material beneath the edges of the two side wall layers 29. The third segment 30 is welded to the inside edges of the two side walls 29. Welds extend over the top and bottom of the radius at the corners of the support surface. These two features: the butt seams 28 at the four corners of the support surface, and the welds, reinforce the high stress corners of the support surface.

[0046] Referring to FIG. 14, in an alternate embodiment, the central apertures 16 are continued through the top and bottom sheets 21, 22, giving the domes at the top of each support surface a doughnut-shaped appearance. The apertures extend through the air support surface. A person reclining on this preferred embodiment of the air support surface 20 could even insert a pencil through the column between the upper and lower central apertures 16 of each support element. Thus, the central apertures of all of the support elements are visible from the top or bottom of the support surface. In this embodiment, no peripheral apertures are present, so the support elements are only open to the ambient air, via the central apertures. The pressurized air does not pass through the support elements. When the support surface is inflated in this embodiment, there is no air transfer between the ambient air inside the support element 10 and pressurized air between the support elements 10 within the support surface 20.

[0047] From the foregoing it can be realized that the described device of the present invention may be easily and conveniently utilized as a support element/surface. It is to be understood that any dimensions given herein are illustrative, and are not meant to be limiting.

[0048] While preferred embodiments of the invention have been described using specific terms, this description is for illustrative purposes only. It will be apparent to those of ordinary skill in the art that various modifications, substitutions, omissions, and changes may be made without departing from the spirit or scope of the invention, and that such are intended to be within the scope of the present invention as defined by the following claims. It is intended that the doctrine of equivalents be relied upon to determine the fair scope of these claims in connection with any other person's product which fall outside the literal wording of these claims, but which in reality do not materially depart from this invention.

[0049] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. 

What is claimed is:
 1. An air inflatable, flexible support element for supporting an air support surface, the support element comprising: (a) two identical circular outer sections, one being an upper outer section and the other being a lower outer section; and (b) two or more circular middle sections, each middle section being affixed at its periphery to the adjacent middle section, each middle section being identical to the other middle sections, each middle section being affixed to an outer section; wherein the outer sections are parallel, but not affixed, to one another; wherein the outer and middle sections each comprise an identically sized central aperture, the central aperture extending through the center of the support element; wherein the support element is substantially comprised of a flexible, nonmetallic, inflatable material.
 2. An air support surface with even stress distribution, the surface comprising: (a) a plurality of identical air support elements, each one comprising two identical circular outer sections, one being an upper outer section and the other being a lower outer section; and two identical circular middle sections, each middle section being affixed at its periphery to the adjacent middle section, each middle section being affixed to an outer section; (b) a top sheet affixed to the upper outer section of each support element within the support surface; (c) a bottom sheet affixed to the lower outer section of each support element within the support surface; wherein the inflatable support elements are generally parallel to one another and transverse to the longitudinal axis of the support surface.
 3. A method of maintaining an air support surface with evenly distributed areas of high and low pressure, comprising the steps of: a) automatically maintaining air pressure in the support surface between self-contained internal support elements; b) ventilating the inside of the support elements to the ambient atmosphere. 